Ignition Coil Case Laser Welding for Joining Quality
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Solution Overview
Problem
Existing ignition coils for internal combustion engines face challenges in achieving stable and efficient part joining, leading to quality issues and prolonged assembly times.
Innovation Solution
The ignition coil design involves a case divided into multiple portions that are laser-welded together to form a storage space for the coil assembly, with insulating resin filled and hardened within the case, minimizing gaps and enhancing material characteristics through precise laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining methods are used to assemble the case from multiple parts, then the manufacturing process is simpler and more accessible, but the joining quality is unstable and assembly time is prolonged
Solution Approach 1:
The patent replaces traditional mechanical joining methods (such as screw fastening or snap-fitting) with laser welding technology. This substitution enables rapid, precise, and stable joining of the case parts while significantly reducing assembly time. The laser welding process provides consistent thermal energy input, ensuring uniform weld quality and eliminating the variability associated with manual or mechanical assembly operations.
Solution Approach 2:
The patent utilizes laser welding parameters (such as laser power, scanning speed, and focal position) to optimize the joining process. By precisely controlling these parameters, the process achieves stable weld quality with consistent strength and appearance. The parameter control system ensures repeatable results across production batches, resolving the quality instability issue while maintaining high productivity through automated parameter management.
2Manufacturing precision
If the case is formed as a single integrated piece, then manufacturing is simpler and fewer parts need assembly, but it becomes difficult to minimize gaps and optimize material characteristics
Solution Approach 1:
The case is divided into multiple separable parts that can be manufactured independently with high precision. This segmentation allows each part to be optimized for its specific function and enables tight tolerances to be achieved in each component. The parts are then joined using laser welding with precise positioning systems that minimize gaps at the joints, achieving overall manufacturing precision that would be difficult to obtain in a single integrated piece.
Solution Approach 2:
Different regions of the case are designed with locally optimized properties. The laser welding process enables localized heating and material modification only at the joining zones, preserving the original material characteristics in the bulk regions. This local quality approach allows the case structure to be optimized for both structural integrity and gap minimization at critical interfaces, while maintaining simplicity in non-critical areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach stabilizes the joining process, improves the quality of the part joining portion, and significantly reduces assembly time while maintaining the functional integrity of the ignition coil.
Implementation Method 1
the parts are joined to each other by laser welding, thereby forming the storage space
Implementation Method 2
the first partial case and the second partial case are joined to each other at a laser welded portion formed by applying laser light to a contact portion
Data Source
AI summary
An ignition coil includes a not-illustrated coil, a plate assembly, and a case assembly. The plate assembly and the case assembly are combined with each other by laser welding at a recess and a rib (projection) which are respective abutting portions, thereby forming storage spaces for storing the coil.